Exide PAR20 User manual

Brand: Exide

Model: PAR20

Type: User manual

This manual is also suitable for

PORTFOLIO PAR20

Exide Technologies –

The Industry Leader.

Installation and Operating

Instructions

For

ABSOLYTE

GX Batteries

SECTION 92.80 2008-07

GNB Industrial Power, a division of Exide Technologies, is a

global leader in stored electrical energy solutions for all major

critical reserve power applications and needs. Network power

applications include communication/data networks, UPS

systems for computers and control systems, electrical power

generation and distribution systems, as well as a wide range of

other industrial standby power applications. With a strong

manufacturing base in both North America and Europe and a

truly global reach (operations in more than 80 countries) in

sales and service, GNB Industrial Power is best positioned

to satisfy your back up power needs locally as well as all over

the world.

Based on over 100 years of technological innovation the Network

Power Division leads the industry with the most recognized

global brands such as ABSOLYTE

, SONNENSCHEIN

MARATHON

, SPRINTER

, RELAY GEL

and GNB FLOODED

CLASSIC

™

. They have come to symbolize quality, reliability,

performance and excellence in all the markets served.

Exide Technologies takes pride in its commitment to a better

environment. Its Total Battery Management program, an

integrated approach to manufacturing, distributing and

recycling of lead acid batteries, has been developed to ensure

a safe and responsible life cycle for all of its products.

GNB Industrial Power

A Division of Exide Technologies

USA – Tel: 888.898.4GNB (4462)

Canada – Tel: 800.268.2698

www.exide.com

TABLE OF CONTENTS

SECTION 1: GENERAL ...................................................................................................................................6

SECTION 2: SAFETY MESSAGES .................................................................................................................6

2.0 General Information.....................................................................................................................6

2.1 Sulfuric Acid Burns ......................................................................................................................6

2.2 Explosive Gases..........................................................................................................................6

2.3 Electrical Shock and Burns .........................................................................................................6

2.3.1 Static Discharge Precautions for Batteries..................................................................................6

2.4 Safety Alert ..................................................................................................................................6

2.5 Important Message......................................................................................................................6

SECTION 3: DELIVERY INFORMATION .........................................................................................................7

3.0 Receipt of Shipment ....................................................................................................................7

3.1 Concealed Damage.....................................................................................................................7

SECTION 4: STORAGE INFORMATION .........................................................................................................7

4.0 Storage Prior to Installation .........................................................................................................7

4.1 Storage Location .........................................................................................................................7

4.2 Storage Interval ...........................................................................................................................7

SECTION 5: INSTALLATION CONSIDERATIONS ..........................................................................................7

5.0 General........................................................................................................................................7

5.1 Space Considerations .................................................................................................................7

5.2 Battery Location & Ambient Temperature Requirements ............................................................7

5.3 Temperature Variations................................................................................................................9

5.4 Ventilation ....................................................................................................................................9

5.5 Floor Loading...............................................................................................................................9

5.6 Floor Anchoring ...........................................................................................................................9

5.7 Connecting Cables: Battery System to Operating Equipment ....................................................9

5.7.1 Paralleling....................................................................................................................................9

5.8 Stacking Limitations...................................................................................................................10

5.9 Terminal Plates ..........................................................................................................................10

5.10 Grounding..................................................................................................................................10

SECTION 6: UNPACKING..............................................................................................................................10

6.0 General......................................................................................................................................10

6.1 Accessories ...............................................................................................................................10

6.2 Recommended Installation Equipment and Supplies................................................................10

6.3 Unpacking ..................................................................................................................................11

6.4 Handling of Modules ..................................................................................................................11

SECTION 7: SYSTEM ARRANGEMENTS.....................................................................................................11

7.0 Module Arrangements................................................................................................................11

SECTION 8: SYSTEM ASSEMBLY ................................................................................................................11

8.0 Module Assembly Identification .................................................................................................11

8.1.1 Bottom Supports (I-beams) .......................................................................................................12

8.1.2 Handling of Modules..................................................................................................................12

8.1.3 Tip Over Procedure ...................................................................................................................12

8.2 Horizontal-Multiple Stacks .........................................................................................................14

8.2.1 Stacking Base Modules .............................................................................................................14

8.2.2 Stack Tie Plates.........................................................................................................................14

8.2.3 Horizontal Stacking....................................................................................................................14

SECTION 9: ELECTRICAL CONNECTIONS .................................................................................................14

9.0 Post Preparation........................................................................................................................14

9.1 Connections - System Terminals...............................................................................................15

9.2 Connections - InterMODULE.....................................................................................................15

9.3 Connections - InterSTACK ........................................................................................................15

9.4 Torquing.....................................................................................................................................15

9.5 Connections - Check .................................................................................................................15

SECTION 10: IDENTIFICATION LABELS........................................................................................................15

10.0 Surfaces ....................................................................................................................................15

10.1 Cell Numerals ............................................................................................................................15

10.2 System Polarity Labels ..............................................................................................................17

10.3 Warning Label............................................................................................................................17

10.4 Battery Nameplate.....................................................................................................................17

SECTION 11: PROTECTIVE MODULE COVERS ...........................................................................................17

11.0 General......................................................................................................................................17

11.1 Transparent Cover Installation ..................................................................................................17

SECTION 12: BATTERY CHARGING ..............................................................................................................17

12.0 Initial Charge .............................................................................................................................17

12.1 Constant Voltage Method ..........................................................................................................17

SECTION 13: BATTERY OPERATION ............................................................................................................19

13.0 Cycle Method of Operation........................................................................................................19

13.1 Floating Charge Method............................................................................................................19

13.2 Float Charge - Float Voltages ...................................................................................................19

13.3 Recharge ...................................................................................................................................19

13.4 Determining State-of-Charge.....................................................................................................19

13.5 Effects of Float Voltage .............................................................................................................20

13.6 Float Current and Thermal Management ..................................................................................20

13.7 AC Ripple ..................................................................................................................................20

13.8 Ohmic Measurements ...............................................................................................................20

SECTION 14: EQUALIZING CHARGE ............................................................................................................20

14.0 General......................................................................................................................................20

14.1 Equalizing Frequency ................................................................................................................21

14.2 Equalizing Charge Method ........................................................................................................21

SECTION 15: RECORDKEEPING ...................................................................................................................21

15.0 Pilot Cell ....................................................................................................................................21

15.1 Voltmeter Calibration .................................................................................................................21

15.2 Records .....................................................................................................................................21

SECTION 16: TAP CONNECTIONS ................................................................................................................22

16.0 Tap Connections........................................................................................................................22

SECTION 17: TEMPORARY NON-USE ..........................................................................................................22

17.0 Temporary Non-Use ..................................................................................................................22

SECTION 18: UNIT CLEANING.......................................................................................................................22

18.0 Unit Cleaning .............................................................................................................................22

SECTION 19 CONNECTIONS MAINTENANCE.............................................................................................22

19.0 Connections...............................................................................................................................22

SECTION 20 CAPACITY TESTING ................................................................................................................22

20.0 Capacity Testing ........................................................................................................................22

LIST OF ILLUSTRATIONS

PAGE FIGURE DESCRIPTION

8 Fig. 1 Typical System Spacing

10 Fig. 2 Packaged Modules

11 Fig. 3 Unpacking Modules

11 Fig. 4 Handling - Lifting Strap Placement

11 Fig. 5 Handling - Module

11 Fig. 6 Typical System Arrangements

12 Fig. 7 I-Beam Hardware Installation

12 Fig. 8 I-Beam Support Installed

12 Fig. 9 Tip-Over Procedure - Shackle-Strap Usage

13 Fig. 10 Tip-Over Procedure - Photo

13 Fig. 11 Module with Base Assembly After Tip-Over

13 Fig. 12 Horizontal Stacking - Shackle-Strap Usage

13 Fig. 13 Handling and Stacking Horizontal Modules

13 Fig. 14 Hardware Installation Sequence

14 Fig. 15 Installing Hardware

14 Fig. 16 Completed Horizontal Stack

14 Fig. 17 Positioning Horizontal Base Modules

14 Fig. 18 Tie Plate Assemblies

15 Fig. 19 Stack Connections

16 Fig. 20 Terminal Plate Kit Materials & Assembly

18 Fig. 21 Protective Cover Materials & Assembly

23 Fig. 22 Sample Record Form

LIST OF TABLES

PAGE TABLE DESCRIPTION

9A Temperature Effects on Life

10 B Absolyte GX Stacking Limitations

17 C Initial Charge Voltages

20 D Float Voltage Effects on Life

21 E Equalize Charge Voltages

APPENDICES

PAGE APPENDIX DESCRIPTION

25 A Temperature Corrected Float Voltages

26 B Maximum Storage Interval Between Freshening Charges

Versus Average Storage Temperature

27 C Bonding and Grounding of Battery Rack

SECTION 1: GENERAL

1.0 General Information

SECTION 2: SAFETY MESSAGES

2.1 Sulfuric Acid Burns

Batteries contain sulfuric acid which can cause burns and

other serious injury. In the event of contact with sulfu-

ric acid, flush immediately and thoroughly with water.

Secure medical attention immediately.

When working with batteries, wear rubber apron and rub-

ber gloves. Wear safety goggles or other eye

protection. These will help prevent injury if contact is

made with the acid.

2.2 Explosive Gases

Hydrogen gas formation is an inherent feature of all lead

acid batteries.

Absolyte GX VRLA batteries, however, significantly

reduce hydrogen formation. Tests have shown that 99%

or more of generated gases are recombined within the

cell under normal operating conditions. Under abnormal

operating conditions (e.g. charger malfunction), the safe-

ty valve may open and release these gases through the

vent. The gases can explode and cause blindness and

other serious injury.

Keep sparks, flames, and smoking materials away from

the battery area and the explosive gases.

All installation tools should be adequately insulated to

minimize the possibility of shorting across connections.

Never lay tools or other metallic objects on modules as

shorting, explosions and personal injury may result.

2.3 Electrical Shock and Burns

Multi-cell systems attain high voltages, therefore, extreme

caution must be exercised during installation of a battery

system to prevent serious electrical burns or shock.

Interrupt the AC and DC circuits before working on

batteries or charging equipment.

Ensure that personnel understand the risk of working with

batteries, and are prepared and equipped to take the nec-

essary safety precautions. These installation

and operating instructions should be understood and

followed. Assure that you have the necessary equipment

for the work, including insulated tools, rubber gloves, rub-

ber aprons, safety goggles and face protection.

2.3.1 Static Discharge Precautions for Batteries

When maintaining a connected battery string, care must

be taken to prevent build-up of static charge. This

danger is particularly significant when the worker is

electrically isolated, i.e. working on a rubber mat or an

epoxy painted floor or wearing rubber shoes.

Prior to making contact with the cell, discharge static elec-

tricity by touching a grounded surface.

Wearing a ground strap while working on a connected

battery string is not recommended.

2.4 Safety Alert

2.5 Important Message

CAUTION!

Before proceeding with the unpacking, handling, instal-

lation and operation of this sealed lead-acid storage

battery, the following information should be reviewed

thoroughly. The safety procedures should be strictly

adhered to when working with Absolyte GX batteries.

DANGER!

SULFURIC ACID BURNS

DANGER!

EXPLOSIVE GASES

CAUTION!

If the foregoing precautions are not fully

understood, clarification should be obtained

from your nearest GNB representative.

Local conditions may introduce situations

not covered by GNB Safety Precautions. If

so, contact the nearest GNB representative

for guidance with your particular safety

problem; also refer to applicable federal,

state and local regulations as well as indus-

try standards.

The safety alert symbol on the left appears

througout this manual. Where the symbol

appears, obey the safety message to avoid

personal injury.

The symbol on the left indicates an impor-

tant message. If not followed, damage to

and/or impaired performance of the battery

may result.

DANGER!

ELECTRICAL SHOCK AND BURNS

HIGH VOLTAGE…

RISK OF SHOCK.

DO NOT TOUCH

UNINSULATED

TERMINALS OR

CONNECTORS.

SECTION 3: DELIVERY INFORMATION

3.0 Receipt of Shipment

Immediately upon delivery, examine packaging for possible

damage caused in transit. Damaged packing material or

staining from leaking electrolyte could indicate rough han-

dling. Make a descriptive notation on the delivery receipt

before signing. If cell or unit damage is found, request an

inspection by the carrier and file a damage claim.

3.1 Concealed Damage

Within 10 days of receipt, examine all cells for concealed

damage. If damage is noted, immediately request an

inspection by the carrier and file a concealed damage

claim. Pay particular attention to packing material exhibiting

damage or electrolyte staining. Delay in notifying carrier

may result in loss of right to reimbursement for damages.

SECTION 4: STORAGE INFORMATION

4.0 Storage Prior to Installation

Do not remove shipping materials if a storage period is

planned, unless charging is required per Section 4.2.

4.1 Storage Location

If the battery is not to be installed at the time of receipt, it

is recommended that it be stored indoors in a cool (25°C,

77°F), clean, dry location.

4.2 Storage Interval

The storage interval from the date of battery shipment to

the date of installation and initial charge should not

exceed six (6) months. If extended storage is necessary,

the battery should be charged at regular intervals until

installation can be completed and float charging can be

initiated. When in extended storage, it is advised to mark

the battery pallets with the date of shipment and the date

of every charge. If the battery is stored at 77°F (25°C) or

below, the battery should be given its initial charge (refer

to Section 10) within 6 months of the date of shipment and

receive a freshening charge (perform per Section 10 Initial

Charge) at 6 month intervals thereafter. Storage at ele

vated temperatures will result in accelerated rates of self

discharge. For every 18°F (10°C) temperature increase

above 77°F (25°C), the time interval for the initial charge

and subsequent freshening charges should be halved.

Thus, if a battery is stored at 95°F (35°C), the maximum

storage interval between charges would be 3 months (ref-

erence Appendix B). Storage beyond these periods with-

out proper charge can result in excessive sulphation of

plates and positive grid corrosion which is detrimental to

battery performance and life. Failure to charge accord-

ingly may void the batteryʼs warranty.

NOTE: Storage in temperatures above 25°C (77°F)

will result in loss of operating life.

Initial and freshening charge data should be saved and

included with the battery historical records (see Section 15).

SECTION 5: INSTALLATION

CONSIDERATIONS

5.0 General

Prior to starting installation of the Absolyte GX

Battery System, a review of this section is

strongly recommended.

5.1 Space Considerations

It is important to know certain restrictions for the area

where the battery is to be located. First, a designated

aisle space should be provided to permit initial installation

as well as for service or surveillance. After installation,

any additional equipment installed after the battery should

not compromise access to the battery system.

A minimum aisle space of 36 inches from modules / 33

inches from clear covers should be available adjacent to

the battery system. See Figure 1 for typical space alloca-

tions required. Following the spacing requirements will

aid in maintenance of the battery and help maintain air

flow to battery surfaces to enhance heat dissipation.

NOTE: When planning system space requirements, allow

at least 6 inches past system total length wherever a ter-

minal plate assembly is to be located (Figure 1A). Allow

4.5” minimum between back to back stacks (Figure 1B).

See Figure 1 for typical space allocations required. For

total length, width and height dimensions of connected

systems, consult layout/wiring diagram for the

particular system.

5.2 Battery Location & Ambient

Temperature Requirements

It is recommended that the battery unit be installed in a

clean, cool, dry location. Floors should be level.

A location having an ambient temperature of 24°C (75°F)

to 25°C (77°F) will result in optimum battery life and

performance. Temperatures below 25°C (77°F) reduce

battery charge efficiency and discharge performance.

Temperatures above 25°C (77°F) will result in a

Any modifications, alterations or additions to an

Absolyte GX system, without the expressed written

consent of GNB Engineering, may void any warranties

and/or seismic qualifications. Contact your GNB

representative for additional information.

TABLE A

TEMPERATURE EFFECTS ON LIFE

Maximum Annual Maximum Percent

Average Battery Battery Reduction

Temperature Temperature In Battery Life

25°C (77°F) 50°C (122°F) 0%

30°C (86°F) 50°C (122°F) 30%

35°C (95°F) 50°C (122°F) 50%

40°C (104°F) 50°C (122°F) 66%

45°C (113°F) 50°C (122°F) 75%

50°C (122°F) 50°C (122°F) 83%

For example: If a battery has a design life of 20 years at

77°F (25°C), but the actual annual average battery

temperature is 95°F (35°C), the projected life of the

battery is calculated to be only 10 years.

The battery temperature shall not be allowed to exceed

50°C (122°F). Minimum battery temperature is -40°C

(-40°F). Temperature records shall be maintained by the

user in accordance with the maintenance schedule pub-

lished in this manual.

5.3 Temperature Variations

Sources of heat or cooling directed on portions of the bat-

tery can cause temperature variations within the strings

resulting in cell voltage differences and eventual compro-

mise of battery performance.

Heat sources such as heaters, sunlight or associated

equipment can cause such temperature variations.

Similarly, air conditioning or outside air vents may cause

cell string temperature variations. Every effort should be

made to keep temperature variations within 3°C (5°F).

5.4 Ventilation

The Absolyte battery is a Valve Regulated Lead Acid

(VRLA) low maintenance design. Tests have confirmed

that under recommended operating conditions in station-

ary applications, 99% or more of gases generated are

recombined within the cell. In most cases, no special

ventilation and or battery room is required. Consult your

local building and fire codes for requirements that may

apply to your specific location.

Hydrogen and oxygen gases can be vented to the atmos-

phere under certain conditions. Therefore, the battery should

never be installed in an air-tight enclosure. Sufficient pre-

cautions must be taken to prevent excessive overcharge.

5.5 Floor Loading

The floor of the area where the battery system is to be

installed should have the capability of supporting the

weight of the battery as well as any auxiliary equipment.

The total battery weight will depend on the cell size, num-

ber of cells, as well as module configuration involved.

Consult layout/wiring diagram for the battery system

weight Prior to installation, a determination should be

made that the floor integrity is adequate to accommodate

the battery system.

5.6 Floor Anchoring

Where seismic conditions are anticipated, floor anchoring

should be provided. Such anchoring is the responsibility

of the user.

Where non-seismic conditions are anticipated, anchoring

is recommended for maximum stability.

Four 9/16” (14.3 mm) holes are provided in the I-Beam for

anchoring.

5.7 Connecting Cables:

Battery System to Operating Equipment

The Absolyte cell is a UL recognized component.

Battery performance is based on the output at the battery

terminals. Therefore, the shortest electrical connections

between the battery system and the operating equipment

results in maximum total system performance.

DO NOT SELECT CABLE SIZE BASED ON CURRENT

CARRYING CAPACITY ONLY. Cable size selection

should provide no greater voltage drop between the bat-

tery system and operating equipment than necessary.

Excess voltage drop will reduce the desired support time

of the battery system.

5.7.1 Paralleling

Where it is necessary to connect battery strings in paral-

lel in order to obtain sufficient load backup time, it is

important to minimize the differences in voltage drop

between the battery strings in parallel in order to promote

equal load sharing upon discharge. Therefore, equal

resistance of cable connections for each parallel string is

important. When paralleling multiple strings to a load or

common bus, please follow these guidelines:

• Each parallel string must have the same number of cells

(same string voltage).

• The cables connecting the positive and negative termi-

nals of each string to the load (or bus) should be of the

same size (i.e. same capacity/cross-sectional area).

• The cables connecting the positive and negative termi-

nals of each string to the load (or bus) should be of the

same length. Choose the shortest cable length that will

connect the battery string that is furthest from the load,

and cut all cables used to connect each string to the load

to this same length.

5.8 Stacking Limitations

There are recommended limits on stacked (horizontal

only) battery configurations, see Table B and consult your

layout/wiring diagram.

TABLE B

Absolyte GX Stacking Limitations for the 2-Cell Tray

GX System Non-Seismic Seismic

GX2000 6 High 6 High

GX3000 6 High 6 High

GX4000 6 High 6 High

GX5000 6 High 6 High

GX6000 6 High 6 High

3-Cell GX2000 trays provide UBC Zone 4 compliance

when stacked 4 modules high and UBC Zone 1 compli-

ance at 8 modules high.

5.9 Terminal Plates

Each system is supplied with a terminal plate assembly

for the positive and negative terminations. These should

always be used to provide proper connection to the oper-

ating equipment and cell terminals.

Any attempt to connect load cables directly to cell termi-

nal may compromise battery system performance as well

as the integrity of cell post seals.

5.10 Grounding

It is recommended that the modules or racks be ground-

ed in accordance with NEC and/or local codes. See

Appendix C for recommended procedure.

SECTION 6: UNPACKING

PACKAGED MODULES

Figure 2

6.0 General

Do not remove shipping materials if a storage period is

planned, unless charging is required per Section 4.2.

The battery modules are generally packed in groups.

Lag bolts retain the modules to the shipping pallet

together with a protective hood bolted in place. Modules

are also bolted together at the top adjacent channels.

See Figure 2.

6.1 Accessories

NOTE: Check accessory package against packing list to

assure completeness. Do not proceed with instal-

lation until all accessory parts are available.

Accessories are packed separately and will include the

following:

• Layout/wiring diagram

• Installation and operating instructions

• Lifting straps and lifting shackles

• Bottom Supports - I beams

• Hardware bag for I beam installation

• Hardware bag for module to module connections

• Standard clear covers

• Top clear covers

• Clear cover mounting brackets and assembly hardware

• Terminal plates

• Terminal plate mounting bracket

• Terminal plate hardware kit

• Terminal Plate Cover and assembly hardware

• Module tie plates and hardware (where required)

• Lead-Tin Plated copper connectors

• Hardware bag for connectors

• NO-OX-ID

“A” * grease

• Battery warning label

• Battery nameplate

• Cell numerals with polarity indicators

• Shims (leveling)

• Seismic Shims (where required)

• Alignment (drift) pins

*Registered Trademark of Sanchem Inc.

6.2 Recommended Installation Equipment

and Supplies

• Fork lift, portable boom crane or A-Frame hoist

— GX2000 Module Weight: 315 kg (695 lb)

— GX3000 Module Weight: 447 kg (985 lb)

—

GX2000 3-Cell Module Weight: 478 kg (1050 lb)

— Bottom Support (I-beams) Height: 10 mm (4 in)

• Chalk line

• Line Cord

• Torpedo level (Plastic)

• Plywood straight edge 1/2” x 4” x 48”

• Torque wrenches (100 in-lbs, 35 ft-lbs)

• Ratchet wrench with 10, 13, 17, 19 mm and

1/2 in. sockets

• Box wrenches 10, 13, 17, 19 mm sizes

• Vinyl electrical tape

• Paper wipers

• 3M Scotch Brite® scour-pads™*

• Hammer drill (Floor anchoring)

* Registered trademark of 3M

6.3 Unpacking

Carefully remove bolts and protective shipping hood. See

Figure 3. Remove the bolts holding modules to shipping

pallet. Also remove hardware bolting upper channels of

modules together. Do not remove modules at this time.

Base supports for horizontally stacked modules are more

easily attached before removing modules from pallet (see

Section 8 System Assembly).

Note: Placement of modules on shipping pallet has

no relationship to final installation and should be

disregarded.

UNPACKING MODULES

Figure 3

6.4 Handling of Modules

The design of the modular tray permits handling by a fork

lift, portable crane or by a hoist sling . Whichever method

is used, make sure equipment can safely handle the mod-

ule weight. See Section 6.2 for module weights.

Always use the two lifting straps and four lifting shackles

for lifting and placement of modules. See Figure 4.

HANDLING - LIFTING STRAP PLACEMENT

Figure 4

NOTE (for Figure 4):

1) Straps must be criss-crossed.

2) Observe lifting shackle orientation

and proper channel hole use.

3) See Figure 13 for handling modules in horizontal

orientation.

4) Never lift more than one module with straps and

hooks.

HANDLING MODULE

Figure 5

SECTION 7: SYSTEM ARRANGEMENTS

7.0 Module Arrangements

Absolyte GX batteries may only be arranged horizontally.

Figure 6 shows some typical arrangements.

TYPICAL SYSTEM ARRANGEMENTS

Figure 6

Modules are shipped without connectors installed. The

wiring diagram enclosed with shipment will show proper

battery hook-up. Module stack height limitation depends on

cell size and the seismic requirements of the application.

SECTION 8: SYSTEM ASSEMBLY

8.0 Module Assembly Identification

Consult layout/wiring diagram for total number and type

of module assemblies in system. Compare required

module assemblies called for on layout/wiring diagram

with modules in shipment for completeness before

continuing further.

The Absolyte GX has a standard module configuration of

two cells per module. Where application voltage requires,

Absolyte GX

3 Stacks

4 High

End to End

Absolyte GX

2 Stacks

6 High

Back to Back

a module may have only one cell in a two-cell tray. For

example, a 46 volt system will consist of eleven full mod-

ules and one single-cell module. Assemblies can be rotat-

ed 180° for proper polarity location.

8.1.1 Bottom Supports (I-beams)

Locate bottom I-beam supports and M10 serrated flange

bolts and nuts. I-beam supports and seismic shims should

be attached to the appropriate module assembly shown

on the layout/wiring diagram prior to removal from ship-

ping pallet. Consult layout/wiring diagram for proper loca-

tion of positive/negative terminals relative to I-beam.

NOTE: Failure to use seismic shims (on systems where

seismic shims are indicated) will result in the

assembly not meeting seismic certification crite-

ria.

Secure I-beam support to a module channel as shown in

Figures 7 & 8, with access slots outward.

Torque hardware to 47 Newton-meters (35 Ft-Lbs) using

insulated tools. The side of the I-beam will be approxi-

mately 3.2mm (.125”) away from the end of the channels.

I-BEAM

HARDWARE INSTALLATION

Figure 7

I-BEAM SUPPORT INSTALLED

Figure 8

Similarly, install the remaining I-beam on the other side of

the module.

8.1.2 Handling

The module/I-beam assembly may now be removed from

the pallet using methods outlined in Section 6.5. See

Figures 4 and 5. Remaining modules may be removed in

a similar manner.

8.1.3 Tip Over Procedure

In order to stack modules in the horizontal position, refer

to Figures 9 through 11 to perform the tip-over procedure.

The module/I-Beam assembly tip-over should be per-

formed first. This procedure can be performed using a

portable boom crane or fork lift in conjunction with the lift-

ing straps and lifting shackles supplied.

A. Install lifting strap using lifting shackles in channel base

holes at each end of module upper front channel as

shown in Figure 9.

B. Center the lifting hook onto strap and lift until strap is

under tension and raises bottom of module from floor

surface.

C. While exerting manual force on the upper front of

module, lower hoist until module is in horizontal posi-

tion. See Figures 10 and 11.

D. After tip over procedure when module is horizontal,

install the four lifting shackles and two lifting straps as

shown in Figure 12 to position and handle battery in

horizontal position.

TIP-OVER PROCEDURE - SHACKLE-STRAP USAGE

Figure 9

NOTE (for Figure 9):

1) One strap with shackles used for

tip-over procedure.

2) Observe channel hole used as well as

direction of shackle insertion.

3) Tip over procedure for single modules only.

TIP-OVER PROCEDURE MODULE AFTER TIP-OVER

Figure 10 Figure 11

HORIZONTAL STACKING SHACKLE-STRAP USAGE

Figure 12

Where floor anchoring is required, position module/I-Beam

assembly in desired location. Mark floor through I-beam

holes and remove module/base assembly. Install floor

anchoring and reposition module/base assembly over

anchoring. Prior to installing nuts and washers, check that

assembly is level in both axes. Level using shims provid-

ed. When level, fasten assembly and torque nuts to 47

Newton-meters (35 Ft-Lbs).

In order to complete stacking of a horizontal single stack

refer to Figures 12 to 15 and steps A through C listed

below.

NOTE: The use of leveling shims is required when

assembling any Absolyte GX system in order to

meet seismic requirements. Failure to use the

shims to level each module and to fill spaces

between tray channels during module assembly

will result in the assembly not meeting seismic

certification criteria. In extreme cases, stack to

stack connectors cannot be installed.

A. Using Section 6.5 and 8.1.3 and the layout/wiring

diagram, position the next module on top of first so that

channels of each mate with one another. Use drift pins

to align channel holes. Make sure channel ends and

sides of the upper and lower modules are flush.

Remove lifting straps and install M10 serrated flange

bolts and nuts in open holes, finger tight. Use leveling

shims to fill gaps between trays. See Figures 13, 14

and 15.

B. At this time, check to see that the first two modules are

plumb front to back and side to side using wooden or

plastic level together with plywood straight edge. This

is to insure proper alignment for module interconnec-

tion later on. Torque hardware to 47 Newton-meters

(35 Ft-Lbs).

C. Proceed with stacking of remaining modules, checking

that stack is plumb in both axes as stacking progress-

es before torquing hardware. Be certain to check the

layout/wiring diagram for correct horizontal orientation

to provide proper polarity interconnection as stacking

progresses. See Figure 16 for completed assembly.

HANDLING AND STACKING HORIZONTAL MODULES

Figure 13

HARDWARE INSTALLATION SEQUENCE

Figure 14

INSTALLING COMPLETED

HARDWARE HORIZONTAL STACK

Figure 15 Figure 16

8.2 Horizontal-Multiple Stacks

8.2.1 Stacking Base Modules

It is recommended that all of the first modules with bottom

supports attached (see Section 8.1.1) be placed in position

first. A chalk line floor mark should be used to assure all

stacks will be in a straight line. This applies for stacks end-

to-end or end-to-end and back-to-back. Refer to Sections

6.5 and 8.1.3 for handling and tip over procedures.

For stacks end-to-end, module ends should be butted

together so that module side channel ends meet (see

Figure 17).

POSITIONING HORIZONTAL BASE MODULES

Figure 17

For stacks back-to-back, the two base modules are posi-

tioned to provide a minimum 4.5” spacing between the

bottoms of the modules (not I-beam edges). Refer back to

Figure 1.

Refer to layout/wiring diagram for seismic shim require-

ments.

8.2.2 Stack Tie Plates

At this time stack tie plates should be installed. It will be

necessary to temporarily remove the hardware fastening

the base modules to the I-beams.

To achieve maximum stack stability, especially where

seismic conditions may exist, as well as proper interfacing

of inter-stack connections, metal tie plates are provided.

The plates used on stacks end to end are 3” x 1” x 1/8”

with two 9/16” holes. Use one tie plate at each interface to

connect the module channels of adjacent stacks. See

Figure 18.

TIE PLATE ASSEMBLIES - HORIZONTAL STACKS

Figure 18

Position plates on the module channels and secure with

hardware as shown. Where stacks have different heights

(for example a 3 high stack adjacent to 4 high stack), install

plates on shorter stack top module and adjacent module.

Torque hardware to 47 Newton-meters (35 Ft-Lbs).

8.2.3 Horizontal Stacking

When all base modules are set in place, continue with

stacking of subsequent modules. Procedures for assem-

bly of multiple horizontal stacks are the same as outlined

in section 8.1.3. Also consult layout/wiring diagram. Each

stack should be built up in sequence to the same level

until the top modules in all stacks are the last to be

installed. The use of a line chord attached to upper mod-

ule corners of opposite end modules as stacking pro-

gresses aids in alignment.

This completes the mechanical assembly of the battery

system.

For installation of intermodular connections and terminal

plate assembly, see Section 9.

For installation of protective module cover, see Section 11.

SECTION 9: ELECTRICAL CONNECTIONS

9.0 Post Preparation

All cell posts were greased at the factory. Using either a

brass bristle suede shoe brush or 3M Scotch Brite scour-

ing pad, brighten the flat copper terminal surfaces to

ensure lowest resistance connections.

TOP MODULE

BASE MODULE

Apply a thin film of NO-OX-ID “A” grease (supplied) to all

terminal surfaces, bolts, and washers. This will

preclude oxidation after connections are completed.

9.1 Connections - System Terminals

Each system is supplied with a terminal plate

assembly for the positive and negative termi-

nations. These should always be used to provide proper

connection to the operating equipment and cell terminals.

Any attempt to connect load cables directly to cell termi-

nal may compromise battery system performance as well

as the integrity of cell post seals.

Refer to layout/wiring diagram for location of terminal plate

assembly in your battery configuration. Assemble Terminal

Support Bracket to module channel using hardware indi-

cated, items 3, 4, 5, 6. Hardware will be located in a bag

labeled K17-417240P for top termination or K17417256 for

side termination. Assemble Terminal Plate to Support

Bracket and battery posts. Hardware to attach to Support

bracket is also located in the terminal plate kit. It is recom-

mended that all connections be torqued to 11 Newton-

meters (100 in-Lbs). After making cable connections,

assemble Terminal Plate Covers, Items 7 & 8, to the Terminal

Support Bracket using hardware indicated. Hardware to

assemble Terminal Plate Covers will be located in the ter-

minal plate kit. Refer to Sections 9.0 and 9.2 for electrical

contact surface preparation of terminal plate components.

Terminal plate assembly varies with termination location.

Refer to layout/wiring diagram termination location on

your battery. Figure 20 shows top termination assembly

with instructions. Do not make connections to operat-

ing system at this time.

9.2 Connections - Inter-MODULE

Consult layout/wiring diagram for correct quantity of lead-

tin plated copper connectors required for each

connection. Follow procedure in Section 9.0 and brighten

lead-tin plated surfaces coming in contact with copper

posts. Apply a thin film of NO-OX-ID “A” grease to these

areas.

NOTE: Apply a minimum amount of grease to cover the

surface. As a rule: "If you can see it, it's too much".

Where multiple connectors are required across any single

connection, brighten both sides of connectors along the

entire length. Grease these areas as well. It is recom-

mended when installing connectors on horizontal

arrangements that the upper bolts be installed first to

reduce risk of accidental shorting.

Refer to layout/wiring diagram for connector placement

and materials list. Figure 19 shows typical module

connections, intrastack connections and interstack

connections.

9.3 Connections - Inter-STACK

Multiple stacks end to end are interconnected as shown in

layout/wiring diagram. Follow the procedures in Sections

9.1 and 9.3.

9.4 Torquing

When all inter-module and inter-stack connections have

been installed, tighten all connections to 11.3 Newton-

meters (100 in-Lbs) Use insulated tools. Recheck connec-

tions after the initial charge due to heating during charge.

STACK CONNECTIONS

Figure 19

9.5 Connection - Check

Again, visually check to see that all module terminals are

connected positive (+) to negative (-) throughout the

battery. Positive terminals have red cap. Negative

terminals have black cap.

Also measure the total open circuit voltage from terminal

plate to terminal plate. This should be approximately

equal to 2.14 volts times the number of cells in the

system, e.g., a 24 cell system would read:

24 x 2.14v = 51.4 volts. An incorrect voltage reading may

mean connectors were installed incorrectly.

SECTION 10: IDENTIFICATION LABELS

10.0 Surfaces

Make sure surfaces are free of dirt and grease by wiping

with clean, dry wipers (isopropyl alcohol may be used) to

ensure proper label adhesion.

10.1 Cell Numerals

A set of pressure sensitive cell numerals and system

polarity labels are supplied and should be applied at this time.

Cell numerals should be applied to the cell being identified.

Designate the positive terminal cell as #1 with succeeding

cells in series in ascending order.

WASHERS SHOULD BE INSTALLED WITH THE CURVED

EDGE TOWARD THE CONNECTORS.

BOLT WASHER CONNECTOR POST

BILL OF MATERIALS — TOP TERMINAL PLATE ASSEMBLY

ITEM DESCRIPTION QTY PER SYSTEM

1 PLATE, TOP TERMINAL 2

2 BRACKET, TERMINAL SUPPORT 2

3 LOCK WASHER, M10 8

4 FLAT WASHER, M10 16

5 NUT, M10 X .8D 8

6 BOLT, M10 X 40 8

7 COVER, FRONT 2

8 COVER, BACK 2

9 NUT, M6 X .8D 4

10 BOLT, M6 X 25 VARIES

11 WASHER, M6 VARIES

Terminal Plate Kit Materials & Assembly

Figure 20

10.2 System Polarity Labels

The system polarity labels should be applied next to the

positive and negative system terminals.

10.3 Warning Label

Apply pressure sensitive warning label provided on a

prominently visible module side or end.

10.4 Battery Nameplate

For future reference and warranty protection, apply

pressure sensitive nameplate on a prominently visible

module. Fill in date of installation and the specified capac-

ity and rate.

SECTION 11: PROTECTIVE MODULE COVERS

11.0 General

Each module is provided with a transparent protective cover

to help prevent accidental contact with live electrical con-

nections, and to provide easy visual access to the system.

When all system assembly has been completed, as well

as initial testing, including initial charge and cell float volt-

age readings, all covers should be installed. Covers

should remain in place at all times during normal opera-

tion of the battery system.

11.1 Module Clear Cover Installation

Refer to Figure 21 for Module Clear Cover installation.

Install standoff legs and standoff keys first, as shown.

The cover is then installed by grasping it so that the GNB

logo is upright. Locate slots at bottom of cover to the bot-

tom standoff legs and slide in place. Locate holes at top of

cover and install to top standoff legs. Refer to Figure 21.

SECTION 12: INITIAL CHARGE

12.0 General

Batteries lose some charge during shipment as well as

during the period prior to installation. A battery should be

installed and given its initial charge as soon after receipt

as possible. Battery positive (+) terminal should be

connected to charger positive (+) terminal and battery

negative (-) terminal to charger negative (-) terminal.

Failure to perform the initial charge within the time

limits stated in section 4.2 will affect the performance

and life of the battery and may void the warranty.

12.1 Constant Voltage Method

Constant voltage is the only charging method

allowed. Most modern chargers are of the

constant voltage type.

Determine the maximum voltage that may be applied to

the system equipment. This voltage, divided by the num-

ber of cells connected in series, will establish the maxi-

mum volts per cell (VPC) that is available. Table C lists

recommended voltages and charge times for the initial

charge. Select the highest voltage the system allows to

perform the initial charge in the shortest time period.

Temperature Correction of Charger Voltage

V corrected = V25°C - ((T actual -25°C) x (.0055 V/°C))

V corrected = V77°F - ((T actual - 77°F) x .003V/°F))

Please refer to Appendix A for standard values.

1. Set constant voltage charger to maximum setting with-

out exceeding 2.35 VPC.

Example: For a target charge of 2.35 VPC on a 24-cell

system, you would set the charger voltage to 56.4 volts.

Depending on the batteryʼs state of charge, the charger

may go into current limit at the beginning and decline

slowly once the target charge voltage is reached.

2. Record time and current at regular intervals – every

hour as a minimum.

3. Continue charging the battery until there is no further

drop in charge current over 3 consecutive hours. This could

take days if the battery has been in storage for a long time.

4. When the current has stabilized, proceed to step 2.

1. Continue the charge for the time listed in Table C

depending on the charger voltage setting. The time is IN

ADDITION to the time spent charging in Step 1.

Example: charge for 12 hours if the charger voltage is set

to 2.35 VPC.

TABLE C

EQUALIZE CHARGE (77°F)

CELL VOLTS TIME (HOURS)

2.30 24

2.33 18

2.35 12

2. Record cell voltages hourly during the last 3 hours of

the charge time. If, after the charge time has completed,

but the lowest cell voltage has continued to rise, you may

extend the charge, monitoring cell voltages hourly, until

the lowest cell voltage ceases to rise.

3. Proceed to Step 3.

STEP 2

STEP 1

Assembly Instructions:

Install standoff legs and standoff keys to module channel as shown. The cover is then installed by grasp-

ing it so that the GNB logo is upright. Locate slots at bottom of cover to bottom standoff legs and slide in

place. Locate holes at top of cover and install to top standoff legs.

Standoff legs need not be removed to access cells, simply remove protective cover.

Module Clear Cover Materials and Assembly

Figure 21

ITEM DESCRIPTION QTY PER SYSTEM

1 Cover 1

2 Standoff Leg 4

3 Standoff Key 4

BILL OF MATERIALS — MODULE CLEAR COVER MATERIALS

1. The initial charge is complete. Charger voltage can

now be reduced to float voltage setting per Section 13.2.

For a target float charge of 2.25 VPC on a 24-cell system,

you would set the charger voltage to 54 volts.

SECTION 13: BATTERY OPERATION

13.0 Cycle Method of Operation

In cycle operation, the degree of discharge will vary for dif-

ferent applications. Therefore, the frequency of recharg-

ing and the amount of charge necessary will vary.

Generally, Absolyte GX cells require approximately 105-

110% of the ampere-hours removed to be returned to a

full state of charge.

The upper voltage settings recommended, given that the

maxium charge current is 5% of the nominal C100

Amp-hour rating and the ambient temperature is 25°C

(77°F), are as follows:

2.28 ± 0.02 VPC @ 0-2% DOD

2.33 ± 0.02 VPC @ 3-5% DOD

2.38 ± 0.02 VPC @ >5% DOD

Due to the variety of applications and charging

equipment (particularly in photovoltaic systems) it is

recommended that you contact a GNB representative

when determining proper recharge profiles.

13.1 Floating Charge Method

In this type of operation, the battery is connected in

parallel with a constant voltage charger and the critical

load circuits. The charger should be capable of

maintaining the required constant voltage at battery

terminals and also supply a normal connected load where

applicable. This sustains the battery in a fully charged

condition and also makes it available to assume the emer-

gency power requirements in the event of an AC power

interruption or charger failure.

13.2 Float Charge - Float Voltages

Following are the float voltage ranges recommended for the

Absolyte Battery System. Select any “volts per cell” (VPC)

value within the range listed that will result in the series

string having an average volts per cell equal to that value.

RECOMMENDED FLOAT RANGE (@77°F)

2.23 to 2.25 VPC

NOTE: Recommended float voltages are for 77°F. For

other temperatures a compensation factor of .003 V/°F

(.0055 V/°C) per cell is recommended. The minimum volt-

age is 2.20 VPC, temperature correction does not apply

below this voltage. The maximum voltage is 2.35 VPC,

temperature correction does not apply above this voltage.

TEMPERATURE CORRECTION

V corrected = V25°C - (( T actual-25°C) x ( .0055V/°C)) or

V corrected = V77°F - ((T actual-77°F) x (.003V/°F))

See Appendix A for standard values.

Modern constant voltage output charging equipment is

recommended for the floating charger method of opera-

tion of GNB Absolyte batteries. This type of charger, prop-

erly adjusted to the recommended float voltages and fol-

lowing recommended surveillance procedures, will assist

in obtaining consistent serviceability and optimum life.

After the battery has been given its initial charge (refer to

Section 12), the charger should be adjusted to provide the

recommended float voltages at the battery terminals

Do not use float voltages higher or lower than those rec-

ommended. Reduced capacity or battery life will result.

Check and record battery terminal voltage on a regular

basis. Monthly checks are recommended. See Section

15.0, Records. If battery float voltage is above or below

the correct value, adjust charger to provide proper voltage

as measured at the battery terminals

13.3 Recharge

All batteries should be recharged as soon as possible fol-

lowing a discharge with constant voltage chargers. To

recharge in the shortest period of time, raise the charger

output voltage to the highest value which the connected

system will permit. Do not exceed the voltages and times

listed in Table E in Section 14.2.

13.4 Determining State-of-Charge

If the normal connected load is constant (no emergency

load connected), the following method can be used to

determine the approximate state-of-charge of the battery.

The state-of-charge can be identified to some degree by

the amount of charging current going to the battery. When

initially placed on charge or recharge following a dis-

charge, the charging current, read at the charger amme-

ter, will be a combination of the load current plus the cur-

rent necessary to charge the battery. The current to the

battery will start to decrease and will finally stabilize when

the battery becomes fully charged. If the current level

remains constant for three consecutive hours, then this

reflects a state-of-charge of approximately 95 to 98%. For

most requirements, the battery is ready for use.

If the normal connected load is variable (i.e. telecommuni-

cations), the following method may be used to check the

state-of-charge of the battery. Measure the voltage across

a pilot cell (See Section 15 for definition of pilot cell). If the

voltage is stable for 24 consecutive hours, the battery

reflects a state of charge of approximately 95%.

STEP 3

13.5 Effects of Float Voltage

Float voltage has a direct effect on the service

life of your battery and can be the cause of

thermal instability.

A float voltage above the recommended values reduces

service life. Table D shows the effects of float voltage

(temperature corrected) on battery life.

TABLE D

FLOAT VOLTAGE EFFECTS ON LIFE

Temperature corrected 25°C (77°F) Percent

Float voltage per cell Reduction

Minimum Maximum in Battery Life

2.23 2.25 0%

2.28 2.30 50%

2.33 2.35 75%

Voltage records must be maintained by the user in accor-

dance with the maintenance schedule published in this

manual. To obtain the optimum service life from the bat-

tery, it is important to make sure the batteryʼs float voltage

is within the recommended range.

13.6 Float Current and Thermal Management

Increased float current can portend a condition known as

thermal runaway, where the battery produces more heat

than it can dissipate. VRLA batteries are more prone to

thermal runaway because the recombination reaction that

occurs at the negative plate, and reduces water loss, also

produces heat. High room temperature, improper applica-

tions, improper voltage settings, and incorrect installation

practices can increase the chances of thermal runaway.

As with good record-keeping practices, monitoring float

current can prevent a minor excursion from becoming a

major issue.

13.7 AC Ripple

AC ripple is noise or leftover AC waveform riding on the

DC charge current to the battery that the rectifier did not

remove. It is usually more pronounced in UPS than tele-

com systems. Proper maintenance of the UPS capacitors

will reduce the amount of ripple going into the battery.

Establishment of absolute limits for AC ripple has always

been problematic because the degree of damage it caus-

es depends on the wave shape, peak-to-peak magnitude

and frequency. Accurate characterization of AC ripple

requires an oscilloscope and even then, only represents a

picture of the ripple at that moment in time.

Whatever its exact characteristics, AC ripple is always harm-

ful to batteries. Depending on its particular properties, ripple

can result in overcharge, undercharge and micro-cycling

that can prematurely age the battery. The most common and

damaging result of AC ripple is battery heating which can

lead to thermal runaway. AC ripple will decrease battery life

and should be reduced as much as possible.

13.8 Ohmic Measurements

Impedance, resistance and conductance testing is collectively

known in the industry as ohmic measurements. Each mea-

surement is derived using a manufacturer-specific and propri-

etary algorithm and / or frequency. This means that one type of

measurement cannot be converted or related easily to another.

“Reference” ohmic values are of dubious value because

so many factors can affect the way the readings are made

and displayed by the devices. Connector configuration

and AC ripple as well as differences between readings of

temperature and probe placement will prevent the ohmic

devices from generating consistent and meaningful data.

The meters work better with monoblocs and small capac-

ity VRLA products and less well with large (>800-Ah)

VRLA and flooded battery designs. Users should be par-

ticularly skeptical of data taken on series-parallel VRLA

battery configurations as the feedback signal to the device

may follow unforeseen paths that can overwhelm it.

It is best for users to establish their own baseline values

for their battery as specifically configured. Do not rely on

reference values.

If users wish to enhance normal maintenance and record-

keeping with ohmic measurements, GNB recommends

the trending of this data over time. Use a first set of read-

ings taken 6 months after initial charge and installation as

the baseline data. Because cell positioning within the

string (connector configuration to a particular cell) can

affect the reading, always compare each cell at baseline

to itself in the new data. Standalone ohmic data is not suf-

ficient to justify warranty cell replacement.

Responsible ohmic device manufacturers acknowledge

that there is no direct relationship between percent ohmic

change from baseline and battery capacity. A change from

baseline of 25% or less is in the normal noise or variability

range. Changes between 25% and 50% may call for addi-

tional scrutiny of the system. An IEEE compliant discharge

test is usually warranted on systems exhibiting more than

a 50% change from baseline. Consult a GNB representa-

tive for specific questions about ohmic data.

SECTION 14: EQUALIZING CHARGE

14.0 General

Under normal operating conditions an equalizing charge

is not required. An equalizing charge is a special charge

given a battery when non-uniformity in voltage has devel-

oped between cells. It is given to restore all cells to a fully

charged condition. Use a charging voltage higher than the

normal float voltage and for a specified number of hours,

as determined by the voltage used.

Non-uniformity of cells may result from low float voltage due

to improper adjustment of the charger or a panel voltmeter

which reads an incorrect (higher) output voltage. Also, vari-

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